Removal of Glycerin From Biodiesel Using An Electrostatic Process

ABSTRACT

A vertical electrostatic coalescer comprises a first and second electrode surface and a horizontally disposed foraminous surface. The first electrode surface and horizontally disposed foraminous surface are at ground potential. The first and second electrode surfaces share the same planar orientation relative to the central longitudinal axis of the vessel. The unique arrangement of the vessel and opposing pairs of first and second electrode surfaces provides for a substantially uniform voltage field around a perimeter of the vessel and an effective voltage field for coalescence within a center of the vessel. A circular-shaped distributor pipe or a distributor housing serves to absorb momentum of the incoming emulsion stream and distribute the stream into an interior of the vessel.

REFERENCE TO PENDING APPLICATIONS

This application is not based upon any pending domestic or internationalpatent applications.

FIELD OF INVENTION

This invention relates generally to electrostatic coalescers, and, moreparticularly, to an improved vertical coalescer to promote separation ofglycerin from biodiesel.

BACKGROUND OF THE INVENTION

Conventional biodiesel production employs homogeneous alkaline catalyststo transform seed oils or animal fats into fatty acid alkyl esters andglycerin. The normal volume ratio of alkyl esters to glycerin is 10:1.Separating the glycerin from the ester layers by capitalizing on theirdifferent specific gravities-1.26 kg/L for glycerin and 0.86-0.90 kg/Lfor esters—is common but cost inefficient.

Large quantities of water are required to remove glycerin and spentcatalyst from the ester layer, which tends to reduce the market value ofthe glycerin byproduct. Static or centrifugal separators are difficultto manage and tedious to operate, lending considerable risk to thequality of the final alkyl ester product, which must meet ASTMspecifications (D6751-07b) before any use in on-road vehicles asbiodiesel.

Newer continuous processes for biodiesel production using heterogeneouscatalysts enable the transeterification reaction to proceedcontinuously. Such continuous processing requires the application ofcost effective, time efficient, and complete separation of glycerin fromthe alkyl ester stream. Because no water is used in these newer solidcatalytic processes, the quality of the glycerin is higher (about 98%)and its market value considerably greater than glycerin from homogeneouscatalytic processes. The lower volume glycerin streams, which typicallyrange from less than 400 barrels per day to as much as 1,000 barrels perday, require a continuous, rapid separation for their economy.

Recent tests conducted by the inventors have shown that glycerin can bereadily and rapidly coalesced by an electrostatic field and theseparation rate is increased by the development of large glycerindroplets. Although electrostatic coalescence is a proven, effectivemethod for crude oil dehydration, electrostatic coalescers are notwell-suited for biodiesel production. These crude oil coalescers aretypically large, horizontally oriented vessels. A need exists,therefore, for smaller, vertically oriented, electrostatic coalescers topromote the separation of glycerin from alky fatty acid esters in thecontinuous production of biodiesel.

BRIEF SUMMARY OF THE INVENTION

An electrostatic coalescer for promoting glycerin coalescence inbiodiesel e comprises an vertically disposed vessel having a fluid inletlocated at a lower portion, a first fluid outlet located at a bottom,and a second fluid outlet located at a top of the vessel. In a preferredembodiment, two or more vertically disposed first and second electrodesurfaces are located in an upper portion of the vessel. The electrodesradially extend outward from and about a central longitudinal axis ofthe vessel. The vessel is at ground potential and a portion of one ormore of the first electrode surfaces is in communication with aninterior surface of the vessel. A portion of one or more of the secondelectrodes is in communication with a power supply. Various types ofpower supply and electric circuitry may be employed to create effectiveelectric fields for coalescence of the glycerin droplets contained inthe emulsion.

Each first electrode surface lies adjacent to a second electrodesurface, and each adjacent first and second electrode surfaces havesubstantially equal angular spacing therebetween. The first electrodesurface preferably has a substantially uniform cross sectional area. Thesecond electrode surface preferably has a teardrop-shaped crosssectional area. The unique arrangement of the vessel and opposing pairsof first and second electrode surfaces provides for a substantiallyuniform AC voltage field around a perimeter of the vessel and aneffective DC field for coalescence within a center of the vessel. Afield in the range of 2 kV/inch to 8 kV/inch is preferable forcoalescing the glycerin.

The electrostatic coalescer further comprises a circular-shapeddistributor pipe or a distributor housing that serves to absorb momentumof the incoming emulsion stream. An array of ports located about aperiphery of the distributor pipe—or an array of ports located on anupper surface of the housing—substantially evenly distributes the streaminto an interior of the vessel. As the glycerin-in-biodiesel streamenters the electric field established by the electrode surfaces,glycerin droplets coalesce. Once the droplets reach a size thatovercomes gravity, the droplets fall to a glycerin phase located at alower portion of the vessel. A level control monitors the glycerin phaseand controls an outlet valve.

In another preferred embodiment, the electrostatic coalescer comprisesone or more horizontally disposed first electrode surfaces located in anupper portion of the vessel. The electrode surface may be a circularshaped bar grate. A portion of the electrode surface is in communicationwith an inner surface of the vessel, which is at ground potential. Twoor more horizontally disposed second electrode surfaces are orientedsubstantially parallel to the first electrode surface and are located asubstantially equal distance above and below the first electrodesurface, respectively. A passageway through the first electrode surfaceallows for a connector to connect the two second electrode surfaces toone another without communicating with the first electrode surface. Thesecond electrode surface may comprise two or more rods of varyinglength, each rod oriented parallel to the other with each end of therods lying a substantially equal distance from an opposing inner surfaceof the vessel. A power supply external to the vessel is in communicationwith one of the second electrode surfaces.

A better understanding of the invention will be obtained from thefollowing description of the preferred embodiments and the claims, takenin conjunction with the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a vertical electrostatic coalescerhaving a circular conduit for distributing an inlet stream of biodieseland glycerin and employing an electric field to coalesce the glycerindroplets in the biodiesel. The electric field comprisescircumferentially arranged and vertically disposed electrode surfaces.

FIG. 2 is a view of the electrostatic coalescer taken along section line2-2 of FIG. 1. Electrode surfaces having a charge alternate with and aresubstantially equally spaced between electrode surfaces at groundpotential.

FIG. 3 is a view taken along section line 3-3 of FIG. 1. A circularconduit having an array of ports serves to absorb momentum of the inletstream and substantially evenly distribute the stream into an interiorof the coalescer.

FIG. 4 is a view taken along section line 4-4 of FIG. 1. A set ofconcentric rings provides support and spacing for the circumferentiallyarranged fin-shaped electrode surfaces

FIG. 5 is view of a typical operating environment for the electrostaticcoalescer.

FIG. 6 is a cross-sectional view of another embodiment of the verticalelectrostatic coalescer having a distributor housing and employing anelectric field. The electric field comprises horizontally disposedelectrode surfaces, one surface having the same charge as a powersupply, the other surface being at ground potential.

FIG. 7 is a view of the electrostatic coalescer taken along section line7-7 of FIG. 6. An open, circular-shaped baffle helps to controlturbulence and a flow of biodiesel to an outlet.

FIG. 8 is a view taken along section line 8-8 of FIG. 6. An electrodesurface at charge comprises a plurality of different length rods, therods being arranged in parallel with each rod end being a substantiallyequal distance from an opposing inner surface of the coalescer.

FIG. 9 is a view taken along section line 9-9 of FIG. 6. An electrodesurface at ground potential comprises a circular bar grate havingcircular passageways therethrough.

FIG. 10 is a view taken along section line 10-10 of FIG. 6.

FIG. 11 is a view taken along section line 11-11 of FIG. 6. Adistributor housing having an array of ports serves to absorb momentumof the inlet stream and substantially evenly distribute the stream intoan interior of the coalescer.

FIG. 12 is a view taken along section line 12-12 of FIG. 6. An open,cylindrical-shaped baffle helps to control turbulence and a flow ofcoalesced glycerin to an outlet.

FIG. 13 is a cross-sectional view of another embodiment of the verticalelectrostatic coalescer having a distributor housing and employing anelectric field. The electric field includes a cylindrical wire screenhaving the same charge as a power supply and a centrally disposed,vertical closed cylinder being at ground potential.

FIG. 14 is a view taken along section line 14-14 of FIG. 13.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An electrostatic coalescer as described below is not limited in itsapplication to the details illustrated in the accompanying drawings. Thecoalescer is capable of other embodiments and of being practiced orcarried out in a variety of ways. The phraseology and terminologyemployed herein, therefore, are for purposes of description and notlimitation. Elements illustrated in the drawings are identified by thefollowing numbers:

-   10 Electrostatic coalescer-   12 Vessel-   14 Vessel top-   16 Vessel bottom-   18 Contact rod-   20 Emulsion inlet-   22 Glycerin outlet-   24 Biodiesel outlet-   26 Support leg-   28 Baffle-   30 Distributor conduit-   32 Port-   34 Distributor housing-   36 Port-   38 Pipe with tee outlet-   40 Brace-   42 Electrode-   44 Fastener-   46 Insulated connector-   48 Support-   50 Electrode-   52 Rod-   54 Fastener-   56 Passageway-   58 Brace-   60 Insulated hanger-   62 Insulated hanger-   64 Ring-   66 Ring-   68 Spoke-   70 Electrode-   72 Electrode-   74 Centralizer-   76 Tab-   78 Cap-   80 Float assembly-   88 Baffle-   90 Power source-   92 High voltage connection-   94 Conductor-   96 Foraminous plate-   98 Electrode-   100 Electrode-   102 Hangar assembly

Referring to FIG. 1, in a preferred embodiment an electrostaticcoalescer 10 comprises a vertically oriented vessel 12 having an inlet20, a heavy component (glycerin) outlet 22, and a lighter component(biodiesel) outlet 24. Positioned within vessel 12 is a first electrodesurface 70 and a second electrode surface 72. Electrode 70 is incommunication with vessel 12, which is at ground potential, via a set oftabs 76. Because glycerin is such a poor conductor, it is preferable toadd a ground in the form of a foraminous plate 96, which is attached tovessel 12 and located in a lower portion of vessel 12. Plate 96 may alsobe a wire screen or bar grate. Electrode 72 is connected by a conductor94 to a power source (not shown). Conductor 94 enters an interior ofvessel 12 through a contract rod 80 located on an exterior surface ofvessel 12. The power source is of a type well known in electrostaticcoalescence and the electrical circuitry employed may incorporatemultiple frequency wave forms. For more detailed information on powersources and related circuitry used in electrostatic coalescence, reviewU.S. Pat. No. 6,860,979, entitled “Dual Frequency ElectrostaticCoalescence” and issued to Gary W. Sams on Aug. 7, 2002, and applicationSer. No. 11/057,900, entitled “Multiple Frequency ElectrostaticCoalescence,” filed Feb. 15, 2005, by Gary W. Sams, both of which arehereby incorporated by reference.

Electrodes 70, 72 form an electric field within an interior of vessel12. The electrodes 70, 72 are oriented so that the glycerin-in-biodieselstream passes between and about adjacent pairs of electrodes 70, 72 andthrough the electric field. As illustrated in FIGS. 2 and 4, eachelectrode 72 preferably has a teardrop-shaped cross sectional area andis suspended vertically by a pair of rings 64, 66 that are orientedhorizontally and arranged concentric to a central longitudinal axis ofvessel 12. Electrode 70 preferably has a substantially uniform crosssectional area. The rings 64, 66, in turn, are suspended by threeinsulated hanger rods 62 which electrically insulate vessel 12 from acharge being applied to ring 64 at connection point 92. Foursubstantially equally spaced spokes 68 connect rings 64 and 66 to oneanother.

The electrodes 72 radially extend outward in relation to a centrallongitudinal axis of vessel 12 so that each electrode 72 relative toeach adjacent electrode 70 preferably has substantially the same angularspacing therebetween. An inner lateral edge and an outer lateral surfaceof each electrode 72 lies a substantially equal distance from anopposing inner surface of vessel 12 and the central longitudinal axis ofvessel 12, respectively. Through the above arrangement, electrodes 72carry a charge but remain insulated from vessel 12 and electrode 70.

Each electrode 70 radially extend outward from a hollow cylindrical-bodycentralizer 74. The electrodes 70 are preferably arranged so that eachelectrode 70 relative to each adjacent electrode 72 has substantiallythe same angular spacing therebetween. Centralizer 74 is arrangedconcentric to the central longitudinal axis of vessel 12 and has aconical-shaped end cap 78 at each end. End cap 78 prevents emulsion fromentering an interior of centralizer 74 and serves to reduce turbulencewithin vessel 12.

A portion of an outer lateral edge of electrode 70 connects to a tab 74located on an inner surface of vessel 12. Adjacent pairs of electrode 70form a space within which an electrode 72 is contained. Each electrode72 has substantially equal angular spacing from each electrode 70. Therelative spacing and shape of electrodes 70, 72 also work to controlturbulence within vessel 12. Additionally, because an exterior surfaceof centralizer 74 is in contact with an inner lateral edge of electrode70, centralizer 74 functions as an electrode. Similarly, an innersurface of vessel 12 functions as an electrode. The configuration andpositioning of electrodes 70 and 72 relative to each other and to vessel12 and centralizer 74 provides for a substantially uniform electricfield preferably in a range of 2 to 8 kV per inch spacing betweenelectrodes 70 and 72.

Returning to FIG. 1, and also referring to FIG. 3, theglycerin-in-biodiesel stream flowing into inlet 20 is routed to adistributor conduit 30, preferably circular shaped. Conduit 30 has anarray of substantially evenly spaced circular-shaped ports 32 locatedabout its periphery 30 a. Conduit 30 absorbs momentum of the incomingglycerin-in-biodiesel stream and reduces its velocity, therebycontrolling turbulence within vessel 12 while distributing the streamsubstantially evenly within vessel 12. As the stream disperses into theinterior of vessel 12 it migrates upwardly toward the electric fieldcreated by electrodes 70 and 72. As the emulsion travels through theelectric field, a bulk of the dispersed glycerin coalesces.

As the coalesced droplets grow in size, gravity overcomes the electricfield that suspends the droplets between the electrodes 70, 72, and thedroplets fall to a glycerin phase collecting at a bottom 16 of vessel12. A float assembly 80 monitors the level of glycerin being collected.Once the level of glycerin reaches a predetermined level, a valve (notshown) opens and allows the glycerin to exit vessel 12 through outlet22.

FIG. 5 illustrates a typical operating environment for the electrostaticcoalescer 10. The transesterification reaction occurs upstream from thecoalescer, whether by the conventional process involving the admixtureof triglycerides, methanol and the homogeneous alkaline catalyst, or bythe newer process employing a heterogeneous, acid catalyst in whichtriglycerides and methanol are admixed and then stirred with the solidcatalyst or passed over a fixed bed containing the solid catalyst. Oncethe reaction is complete, the feed to the electrostatic separator ineither case, containing biodiesel and glycerin, will have been cooledand stripped of residual methanol and water, as appropriate. This feedto the electrostatic coalescer 10 will consist of biodiesel and glycerinin an approximate ratio by volume of 10:1.

Referring now to FIG. 6, another preferred embodiment of electrostaticcoalescer 10 is illustrated. In this embodiment, electrodes 42 and 50form an electric field. Electrode 42 is in communication with vessel 12,which is at ground potential, via a fastener 44 that attaches electrode42 to an internal brace 58. Foraminous plate 96 is also at groundpotential. Electrode 50 is connected to a power source (not shown) by aconductor 94 and is suspended by insulated hangers 62 that connect to anelectrode supporting structure 46. The electrodes 42, 50 are eachoriented in a horizontal plane, with a pair of electrodes 50 a and 50 bbeing positioned substantially parallel to and a substantially equaldistance above and below electrode 42, respectively. An insulatedconnector 46 connects electrodes 50 a and 50 b.

As illustrated in FIGS. 8 and 10, electrode 50 preferably comprises aseries of varying length rods 52 a, 52 b, each rod 52 a, 52 b being heldby a pair of fasteners 54 and arranged so that adjacent rods 52 a, 52 bare parallel to one another and the end of each rod 52 a, 52 b lies asubstantially equal distance from an opposing inner surface of vessel12. As illustrated in FIG. 9, electrode 42 preferably comprises acircular-shaped bar grate being arranged concentric to vessel 12 andhaving two circular-shaped passageways 56 located on its interiorsurface. Insulated connector 50 passes through passageway 56, therebyisolating electrodes 42 and 50 from one another. The relative spacingand shapes of electrodes 42, 52 also work to control turbulence withinvessel 12.

Returning to FIG. 6, and also referring to FIGS. 7, 11, and 12, theglycerin-in-biodiesel stream flowing into inlet 20 is routed to pipe 38having a tee at one end and being located within a distributor housing34. One end of the tee of pipe 38 mates against a bottom surface ofhousing 34, the other end faces an array of substantially evenly spacedcircular-shaped ports 36 located on an upper surface of housing 34.Housing 34 and pipe 38 absorb momentum of the incomingglycerin-in-biodiesel stream and reduce its velocity, therebycontrolling turbulence within vessel 12 while distributing the streamsubstantially evenly within vessel 12.

As the stream disperses into the interior of vessel 12 it migratesupwardly toward the electric field created by electrodes 42 and 50. Asthe stream travels through electric field F, a bulk of the dispersedglycerin coalesces. As the coalesced droplets grow in size, gravityovercomes the electric field F that suspends the droplets between theelectrodes 42 and 50 and the droplets fall to a glycerin phasecollecting at a bottom 16 of vessel 12. A circular-shaped open-topbaffle 48 serves to control a flow of glycerin to outlet 22. Similarly,a circular-shaped open-bottom baffle serves to control the flow ofbiodiesel to outlet 24.

FIGS. 13 and 14 illustrate another embodiment of electrostatic coalescer10. In this embodiment, electrodes 98 and 100 form an electric field.Electrode 98 is a foraminous surface, preferably a cylindrical wirescreen, connected to a power source (not shown) by conductor 94 andsuspended by insulated hangers 62. Electrode 100 is a solid surface,preferably a hollow, closed end, cylinder in communication with vessel12, which is at ground potential, via a hanger assembly 102. Theelectrodes 98, 100 are each oriented in a vertical plane. Foraminousplate 96 is at ground potential.

While electrostatic coalescer 10 has been described with a certaindegree of particularity, many changes may be made in the details ofconstruction and the arrangement of components without departing fromthe spirit and scope of this disclosure. The invention, therefore, islimited only by the scope of the attached claims, including the fullrange of equivalency to which each element thereof is entitled.

1-16. (canceled)
 17. An electrostatic coalescer for promoting glycerincoalescence in a biodiesel stream comprising: an elongated, closed,vertically disposed vessel having a fluid inlet located at a lowerportion, a first fluid outlet located at a lower portion of said vesseland a second fluid outlet located at a top portion of said vessel; atleast one horizontally disposed first electrode surface located in anupper portion of said vessel, a portion of said first electrode surfacebeing in communication with an interior surface of said vessel; aplurality of horizontally disposed second electrode surfaces beingconnectable to each other and located substantially parallel to and asubstantially equal distance above and below said first electrodesurface, a power supply external to said vessel and in communicationwith said second electrode surfaces; whereby said first and secondelectrode surfaces establish effectively a voltage field around aperimeter portion of said vessel and in a center portion of said vessel,the voltage field serving to coalesce glycerin in the stream to augmentseparation thereof from the stream.
 18. An electrostatic coalesceraccording to claim 17 further comprising a horizontally disposedforaminous surface located in a lower portion of said vessel and incommunication with an interior surface of said vessel.
 19. Anelectrostatic coalescer according to claim 17 further comprising atleast one of said first electrode surfaces and said second electrodesurfaces having a grid arrangement.
 20. An electrostatic coalesceraccording to claim 17, said second electrode surface comprising aplurality of rods oriented substantially parallel to one another, eachrod having a first and second end, said first and second ends being asubstantially equal distance from an opposing interior surface of saidvessel.
 21. An electrostatic coalescer according to claim 17 furthercomprising one or more connector passageways, said passageway beinglocated on an interior surface of said first electrode surface andallowing for one or more connectors connectable to said second electrodesurface to pass therethrough.
 22. An electrostatic coalescer accordingto claim 17 wherein a voltage between each opposing pair of first andsecond electrode surfaces is in a range of 2 kV/inch to 8 kV/inch. 23.An electrostatic coalescer according to claim 17 further comprising adistributer housing, said distributor housing being connectable to saidinlet and having an array of ports located at an upper portion of saiddistributor housing.
 24. An electrostatic coalescer according to claim17 further comprising a level control located in a lower portion of saidvessel.
 25. An electrostatic coalescer for promoting glycerincoalescence in a biodiesel stream comprising: an elongated, closed,vertically disposed vessel having a fluid inlet located at a lowerportion, a first fluid outlet located at a lower portion of said vesseland a second fluid outlet located at a top portion of said vessel; avertically disposed cylindrical-shaped first electrode surface locatedin an upper portion of said vessel and arranged about a centrallongitudinal axis of said vessel, a portion of said first electrodesurface being in communication with an interior surface of said vessel;a vertically disposed cylindrical-shaped second electrode surfacelocated in an upper portion of said vessel and arranged about said firstelectrode surface with a circumferential space therebetween; a powersupply external to said vessel and being in communication with saidsecond electrode surfaces; whereby said first and second electrodesurfaces establish effectively a voltage field around a perimeterportion of said vessel and in a center portion of said vessel, thevoltage field serving to coalesce glycerin in the stream to augmentseparation thereof from the stream.
 26. An electrostatic coalesceraccording to claim 25 further comprising a horizontally disposedforaminous surface located in a lower portion of said vessel and incommunication with an interior surface of said vessel;
 27. Anelectrostatic coalescer according to claim 25 wherein a portion of saidfirst electrode surface comprises a hollow closed end body and a portionof said second electrode surface comprises a foraminous surface.
 28. Anelectrostatic coalescer according to claim 25 further comprising acircular-shaped distributor conduit, said distributor conduit being incommunication with said fluid inlet and having an array of ports.
 29. Anelectrostatic coalescer according to claim 25 further comprising a levelcontrol located in a lower portion of said vessel.